TP-6735 7/1742 Section 4 Controller
4.6 Exercise
The RDC and DC controllers can be set to automatically
run the generator set at the same time and day each
week. Exercising the generator set weekly is required in
order to keep the engine and alternator in good
operating condition.
Follow the instructions in this section to start a
20-minute exercise run and set the exerciser to r un at
thesametimeevery7days.
Note: RDC controllers with firmware version 2.08 or
higher support the unloaded variable-speed
exercise with Kohler Model RRT, RDT, and RSB
transfer switches.
Note: With the RDT and RSB transfer switches, it is
possible to have two exercise settings (one set at
the generator set controller, and one set at the
ATS controller). If the exercise times overlap, the
ATS exercis e setting takes priority.
Set the exercise at the RDC/DC controller or the ATS
controller as s hown in Figure 4-7. If a Model RDT or
RSB transfer switch is used, refer to the instructions
provided with the transfer switch to s et an exercise at
the ATS.
Transfer
Switch
Model
Exercise
Unloaded
Variable
Speed
Unloaded
Full Speed
Loaded Full
Speed
RRT RDC/DC N/A RDC/DC
RDT RDC/DC ATS ATS
RSB RDC/DC ATS ATS
Figure 4-7 Setting the Exerciser
4.6.1 Unloaded Variable-Speed Exercise
with Complete System
Diagnostics
An unloaded exercise runs the generator set without
signalling the transfer switch to transfer the electrical
load from the utility source to the generator set.
In an unloaded exercise with controller firmware
versions prior to 2.08, the generator runs at low speed
for 20 minutes and then shuts down.
Note: If the engine temperature has risen to 104_C
(219_F) or higher, the unit will run at full speed for
5 minutes to allow engine cooldown before
shutting down.
With controller firmware version 2.08 or higher, the
unloaded variable-speed exercise runs at low speed for
15 minutes, then ramps up to full speed during the last 5
minutes (firmware version 2.08 or higher).
The initial low-speed exercise allows generator set
exercise at lower noise levels and fuel consumption
while properly warming up the engine for longer life and
better lubrication of critical components.
The full-speed portion of the exercise cycle provides the
best test of engine and alternator power backup
capability. Diagnostic tests at full speed can identify
potential problems with the power output and alert the
operator before an emergency event.
Procedure to Set Unloaded Variable-Speed
Exercise
1. Verify that the control is in the AUTO mode with the
AUTO LED ON and the Utility power available.
2. Press the down arrow button (RDC) or exercise
button (DC) to initiate the engine start signal.
3. The generator begins its crank cycles. During the
crank cycles CCn appears on the display. No
button presses are acknowledged during the crank
cycles.
4. The generator runs at low speed for 15 minutes.
EnLd appears on the display. The AUTO LED is
illuminated. The controller monitors the system
during the unloaded exercise as described in
Section 4.6.2, D iagnostics.
5. During the last 5 minutes, the engine ramps up to
full speed and then shuts down. Generator output
frequency and voltage diagnostics are active as
described in Section 4.6.2, D iagnostics.
The exercise time is set to the time the down arrow or
exercise button is pressed. An unloaded diagnostic
exercise will occur at the same time every seven days.
4.6.2 Diagnostics
During the unloaded variable-speed exercise, the
controller monitors the following data. The controller
display indicates an unloaded exercise run ( EnLd)
during the diagnostics, unless a fault is detected as
described below.
D ATS connection. The controller verifies that the ATS
interface board, if connected, remains c onnected. An
ATS fault is displayed if the connection is lost.
D Battery voltage. Battery voltage is checked before
exercise to verify engine starting capability. Battery
voltage provides a measurement of battery health. If
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